Multi-Layer Blow Molded Article with Functional Visual and/or Tactile Effects

ABSTRACT

Blow molded articles having a predetermined feature incorporated into the wall provided by variations in the thickness of the wall of the article corresponding to a predetermined pattern etched into the perform from which the article was formed. Also, etched performs for making blow molded articles and methods for making such performs and articles.

FIELD OF THE INVENTION

The present invention relates to blow molded articles, performs for blowmolded articles, and methods for making such articles and performs.

BACKGROUND OF THE INVENTION

Blow molded articles made of thermoplastic materials are popular invarious industries, including the consumer goods and food industries.For example, containers such as bottles for liquid products are oftenmade via blow molding. During the blow molding process, a perform isexpanded in a mold, generally with air or another gas under highpressure, to form the resulting article. For certain articles, stretchblow molding is used where the perform is softened and/or stretchedwhile in the mold prior to being expanded into the final article.

Although blow molding has been found to be an effective and efficientprocess for manufacturing articles such as containers and the like, therequirements of the process can make it difficult to provide articleswith certain aesthetic, functional, and/or tactile qualities orcharacteristics. For example, it may be desirable to provide an articlewith a textured outer surface, an appearance of a textured outer surfacewith a smooth outer surface (e.g. to ensure a label can be easilyapplied thereto), and/or different colors, indicia, decoration and/ortext visible when looking at the outer surface. However, the blowmolding process often limits the available options for the appearance ofthe outer surface of the article because of how performs are formed, thehigh cost of the molds for the blow molding process and the processingrequirements needed to blow the perform into the final article.

Thus, it would be desirable to provide improved aesthetic, functional,and/or tactile features on blow molded articles. It would also bebeneficial to provide an improved process for manufacturing blow moldedarticles to allow for a greater range of aesthetic, functional, and/ortactile features. It would also be desirable to provide an improvedmethod of forming performs for blow molded articles that allows theresulting blow molded articles to have a greater range of aesthetic,functional, and/or tactile features and/or to allow the tactile,functional, and/or aesthetic features to be changed quickly and costeffectively. Further still, it would be desirable to provide improvedaesthetic, functional, and/or tactile features on blow molded articleswhile keeping the process simple, cost-effective and scalable to massmanufacture and allowing for the resulting articles to have portions orall of the outer surface smooth so as to allow for easy attachment of alabel.

SUMMARY OF THE INVENTION

The present invention provides a solution for one or more of thedeficiencies of the prior art as well as other benefits. Thespecification, claims and drawings describe various features andembodiments of the invention, including a multi-layer blow moldedarticle formed from a perform etched in a predetermined pattern. Thearticle comprises a neck forming an opening; a body portion extendingfrom the neck to a base, the body portion including one or more wallssurrounding an interior space in fluid communication with the opening,the one or more walls having an article inner surface, an article outersurface, and a thickness; a predetermined feature incorporated into atleast a portion of the one or more walls, wherein the predeterminedfeature is provided by variations in the thickness of the one or morewalls corresponding to the predetermined pattern.

Also disclosed is a multi-layer perform for blow molding formed from athermoplastic material, the perform comprising a body having one or morewalls and an opening, wherein at least a portion of the body includes anetched portion having at least some of the thermoplastic materialremoved in a predetermined pattern.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a plan view of a perform in accordance with the presentdisclosure.

FIG. 2 is an enlarged cross-section view of the perform of FIG. 1 takenthrough 2-2.

FIG. 3 is a plan view of a perform in accordance with the presentinvention as it is being laser-etched.

FIG. 3A is a cross-sectional view of the perform of FIG. 3 taken throughcross-section line 3A-3A.

FIG. 3B is an enlarged view of portion 60 of the perform shown in FIG.3A.

FIG. 4 is a plan view of a blow molded article in accordance with thepresent invention.

FIG. 4A is cross-sectional view of the perform of FIG. 4 taken throughcross-section line 4-4.

FIG. 4B is an enlarged view of portion 60 of the perform shown in FIG.3A.

FIG. 4C is an enlarged view of portion of a perform in accordance withthe present invention.

FIG. 4D is an enlarged view of portion of a blow molded article inaccordance with the present invention.

FIG. 4E is an enlarged view of portion of a perform in accordance withthe present invention.

FIG. 4F is an enlarged view of portion of a blow molded article inaccordance with the present invention.

FIG. 4G is an enlarged view of portion of a perform in accordance withthe present invention.

FIG. 4H is an enlarged view of portion of a blow molded article inaccordance with the present invention.

FIG. 5 is a plan view of a blow molded article in accordance with thepresent invention.

FIG. 6 is a plan view of a blow molded article in accordance with thepresent invention.

FIG. 6A is a cross-sectional view of a blow molded article in accordancewith the present invention.

FIG. 6B is a cross-sectional view of a perform for a blow molded articlein accordance with the present invention.

FIG. 7A is a plan view of a blow molded bottle in accordance with thepresent invention.

FIG. 7B is a plan view of a blow molded bottle in accordance with thepresent invention.

FIG. 8 is a cross-sectional view of an exemplary mold for forming aninjection-molded perform.

FIG. 9 is a perspective view of a perform being etched by a laser.

FIG. 10 is a cross-sectional view of a blow mold in accordance with thepresent invention.

DETAILED DESCRIPTION OF THE INVENTION

“Article”, as used herein refers to an individual blow molded hollowobject for consumer usage, e.g. a container suitable for containingmaterials or compositions. The article may be a container, non-limitingexamples of which include bottles, tubes, drums, jars, cups, and thelike. The compositions contained in such a container may be any of avariety of compositions including, but not limited to, detergents (e.g.,laundry detergent, fabric softener, dish care, skin and hair care),beverages, powders, paper (e.g., tissues, wipes), beauty carecompositions (e.g., cosmetics, lotions), medicinal, oral care (e.g.,tooth paste, mouth wash), and the like. Containers may be used to store,transport, and/or dispense the materials and/or compositions containedtherein.

“Blow molding” refers to a manufacturing process by which hollowcavity-containing articles are formed. In general, there are three maintypes of blow molding: extrusion blow molding (EBM), injection blowmolding (IBM), and injection stretch blow molding (ISBM). The blowmolded articles of the present invention can be made via IBM and ISBM orany other known or developed blow molding method, all of which arereferred to herein simply as blow molding. The blow molding processtypically begins with forming a precursor structure or “perform” that isultimately expanded into the final article. The perform, as used herein,can be any shape or configuration, but is often in the general shape ofa tube with at least one open end, or two open ends. Examples ofperforms include, but are not limited to, parisons (the name often givento precursor structures used in extrusion blow molding), performs, andother precursor structures used in different blow molding techniques.Performs, as used herein, can be formed by extrusion, injection,compression molding, 3D printing and other know or developed methods.Injection molding of the perform can be simple injection molding of asingle material, co-injection of two or more materials in a single stepand/or over-molding preformed in two or more steps. The injection stepcan be closely coupled to a blowing step, as in IBM, 1-step ISBM or1.5-step ISBM, or can be decoupled in a secondary operation such as2-step ISBM. During blow molding, a perform or other precursor structureis typically clamped into a mold and a fluid, often compressed air, isdirected into the perform through the opening to expand the perform tothe shape of the mold. Sometimes the perform is mechanically stretchedprior to or at the same time the fluid is introduced (known as “stretchblow-molding”). Also, the perform may be heated or cooled before thefluid is introduced. The pressure created by the fluid pushes thethermoplastic out to conform to or partially conform to the shape of themold containing it. Once the plastic has cooled and stiffened, the moldis opened and the formed article is ejected.

The term “etch” as used herein as a noun, refers to the cavity formedwhen material is removed from a surface. As a verb, the terms “etch” and“etching” refers to the act of removing material from a surface. Etchingcan be performed mechanically, chemically and thermally (e.g. laser).Although there is no specific limitation on the maximum or minimum depthof an etch, etching depths are typically in the range of about 0.001mmto about 2.0mm, including any depth within the range, such as forexample, 0.010 mm, 0.075 mm, 0.100 mm, 0.200 mm, 0.300 mm, 0.400 mm,0.500 mm, 1.0 mm, 1.5 mm and others.

The term “layer” in the context of the present invention means athickness of material that is generally continuous and typicallyhomogeneous in terms of its chemical makeup. However, it is contemplatedthat any particular layer may have discontinuities and/ornon-homogeneous materials or regions in certain configurations.

The term “translucent” as used herein means the material, layer,article, or portion of the article being measured has total luminoustransmittance of greater than 0% and less than or equal to 90%. The term“transparent” as used herein means the material, layer, article, orportion of the article being measured has total luminous transmittanceof 90% or more. The term “opaque” as used herein means the material,layer, article, or portion of the article being measured has totalluminous transmittance of 0%. The total luminous transmittance ismeasured in accordance with

Perform:

As noted above, performs are commonly used in blow molding processes. Anexemplary perform 10 is shown in FIG. 1. The perform 10 has a body 12,and at least one open end 16 having an opening 34. The perform 10 mayalso include a neck or finish 14, and a closed end 18 disposed oppositeof the open end 16. The finish 14 of the perform 10 may include one ormore threads 20 or other structures that can be used in the resultingarticle to engage with a cap or other closure device. The neck 14 canalso include a transfer ring 22 or other structure that can aid in themanufacturing process.

The perform 10 can be used in a blow molding process to provide apreliminary structure that can be transformed into a final article, suchas a bottle, by means of directing a pressurized fluid into the open end16 of the perform 10 while the perform 10 is disposed in a mold in theshape of the final article (or an interim article). Typically, theperform 10 may be heated or otherwise manipulated mechanically orchemically to soften the material of the perform 10 prior tointroduction of the pressurized fluid to allow the perform 10 to expandinto the shape of the mold without shattering or cracking. More detailsrelating to exemplary blow molding processes in accordance with thepresent invention are described below.

Generally, the perform 10 is formed separately from the blow moldingstep. The perform 10 can be formed by any suitable method, including butnot limited to molding, extrusion, 3D printing, or other known ordeveloped processes. The perform 10 may be formed from a single materialor may include layers or regions of different materials. FIG. 2 is anenlarged cross-section of the perform 10 shown in FIG. 1 taken throughsection line 2-2. As shown, the perform 10 includes one or more performwalls 30, closed end 18 and interior space 36. The perform walls 30 havean inner surface 32 adjacent the interior space 36 and an outer surface33 forming the exterior of the perform 10. Typically, but notnecessarily, the perform walls 30 are between about 1.0 mm and about 6mm thick. The perform walls 30 are shown as having three layers, outerlayer 40, intermediate layer 42 adjacent to, but inward from outer layer40, and inner layer 44. Although three layers are shown, any number oflayers can be used, including a single layer, two or more layers, threeor more layers or any other number of layers. Also, although the layersare shown to extend throughout the entire length of the perform 10, anyone or more layers may extend only part way through the perform 10.Further, the layers 40, 42 and 44 may each have a thickness, T1, T2 andT3. The thickness T1, T2, and T3 of each layer 40, 42 and 44 may be thesame or may be different from one or more of the other thicknesses. Thelayers 40, 42 and 44 may be made of the same material or differentmaterials. They may also be the same or different colors or have thesame or different luminous transmittance. For example, the outer layer40 may be transparent and the inner layer 44 or intermediate layer 42may have a color or be translucent or opaque, although any othercombinations of layers with the same or different luminous transmittanceare contemplated. By including layers with different colors and/ordifferent luminous transmittance, the article formed from the perform 10can have interesting and/or unique aesthetic characteristics.

A perform or article according to the present invention may be formed ofa single thermoplastic material or resin or from two or more materialsthat are different from each other in one or more aspects. Where theperform 10 has different layers, the materials making up each of thelayers can be the same or different from any other layer. For example,the perform or article may comprise one or more layers of athermoplastic resin, selected from the group consisting of polyethyleneterephthalate (PET), polyethylene terephthalate glycol (PETG),polystyrene (PS), polycarbonate (PC), polyvinylchloride (PVC),polyethylene naphthalate (PEN), polycyclohexylenedimethyleneterephthalate (PCT), glycol-modified PCT copolymer (PCTG), copolyesterof cyclohexanedimethanol and terephthalic acid (PCTA), polybutyleneterephthalate (PBCT), acrylonitrile styrene (AS), styrene butadienecopolymer (SBC), or a polyolefin, for example one of low-densitypolyethylene (LDPE), linear low-density polyethylene (LLPDE),high-density polyethylene (HDPE), propylene (PP) and a combinationthereof.

Recycled thermoplastic materials may also be used, e.g., post-consumerrecycled (“PCR”) materials, post-industrial recycled (“PIR”) materialsand regrind materials, such as, for example polyethylene terephthalate(PCRPET), high density polyethylene (PCRHDPE), low density polyethylene(PCRLDPE), polyethylene terephthalate (PIRPET) high density polyethylene(PIRHDPE), low density polyethylene (PIRLDPE) and others. Thethermoplastic materials may include a combination of monomers derivedfrom renewable resources and monomers derived from non-renewable (e.g.,petroleum) resources. For example, the thermoplastic resin may comprisepolymers made from bio-derived monomers in whole, or comprise polymerspartly made from bio-derived monomers and partly made frompetroleum-derived monomers.

The thermoplastic resin can have a relatively narrow weightdistribution, e.g., metallocene PE polymerized by using metallocenecatalysts. These materials can improve glossiness, and thus in themetallocene thermoplastic execution, the formed article has furtherimproved glossiness. Metallocene thermoplastic materials can, however,be more expensive than commodity materials.

One benefit of the present invention is that it allows aesthetic,functional and/or textural features to be added to injection blow molded(IBM) articles and injection stretch blow molded (ISBM) articles thatcould not otherwise be achieved. This is important because such IBM andISBM can be made from PET, which is often preferred over other materialsbecause PET is more universally recycled than other clear and glossythermoplastic materials. The present invention allows for IBM and ISBMarticles to be made that have smooth outer surfaces and textured innersurfaces which can provide unique and aesthetically pleasing designs.Although EBM articles can be provided with certain textured surfaces,due to the nature of the extrusion blow molding process (typically usingPETG), the range of textures is limited, and the resulting products tendto be less easily recycled than IBM and ISBM articles containing onlyPET. The “G” in PETG refers to glycol modified PET copolymer in whichsome of the ethylene glycol is replaced with a second glycol,cyclohexane dimethanol (CHDM) and it is generally considered acontaminant in recycling streams and can negatively impact theperformance and processability of PET. Thus, improvements in theaesthetic, textural and/or functional features of IBM and ISBM articlesis highly desirable.

The perform 10 can be formed by any known or developed method. Forexample, the perform 10 can be formed by injection, co-injection and/orover-molding as well as less conventional techniques like compressionmolding, 3D printing or the like. The perform 10 may be formed such thatat least a portion of the perform walls 30 includes some texture, e.g.lines, dots, a pattern, and/or indicia, or they may be formed to besmooth. If the perform 10 is formed in a mold and a surface includestexture, it important to ensure the texture does not interfere withremoval of the perform 10 from the mold. This can be done by limitingthe height, fineness or density of any texture and/or selecting atexture with peaks and valleys that generally run parallel to thedirection in which the perform 10 is removed from the mold. For example,it may be required to limit the depth of any texture that creates anundercut perpendicular to the direction of demolding to less than about50 microns. This is especially true for PET materials which tend to havehigher stiffness compared to PP or HDPE materials and thus, may sheerrather deform and rebound during the demolding process. Some of thelimitations related to texturing the perform 10 by means of the performmold can be avoided by the method described herein and/or by 3D printingof the perform.

In accordance with one aspect of the present invention, the outersurface 33 of the perform 10 may be modified after it is formed tochange the topology of the outer surface 33. Methods for modifying theouter surface 33 of the perform 10 include, but are not limited tolaser-etching, water jets, cold pressing, hot pressing, milling, etc.The outer surface 33 may be modified to form lines, dots, patters,and/or indicia in or on the outer surface 33. FIG. 3 shows an exemplaryembodiment of a perform 10 that is being laser-etched by the beam 50 oflaser 52, although any other suitable technique may be employed. Thelaser beam 50 removes a portion of the material forming the outersurface 33 of the perform resulting in a texture on the outer surface33. It is also contemplated, though, that material may be added to theouter surface 33 to provide the texture, such as predetermined pattern54. The predetermined pattern 54 may take on any desired shape,including repeating and/or random pattern, lines, dots, curves, letters,numbers or any other desired indicia. Since the modification of theouter surface 33 of the perform 10 takes place after the perform 10 isremoved from the mold in which it is formed, there are few, if any,limitations on the particular texture or pattern 54 that can be used.This also allows for different performs 10 from the same mold to havedifferent textures which can significantly reduce the cost of producingarticles with different aesthetic, functional and/or textural qualitieswhich, in turn, can make production of small numbers of articles andeven customized articles economically feasible. FIG. 3A iscross-sectional view of the perform of FIG. 3 taken through section line3A-3A of FIG. 3. The exemplary embodiment shown in FIG. 3 has threelayers in the perform wall 30. Layer 40 is the outer layer, layer 42 isthe intermediate layer and layer 44 is the inner layer. As can be seen,the laser-etching removes material from the perform 10. Specifically, inthe embodiment shown in FIGS. 3A, the laser-etching removed portions ofthe outer layer 40. However, the laser 52 can be used to remove portionsof other layers in addition to or instead of the outer layer 40.

FIG. 3B is an enlarged view of a portion 60 of the perform 10 shown inFIG. 3A. As shown, the laser-etching can remove all or a portion of oneor more of the layers 40, 42 and 44. The depth D of the laser etchingcan be the same as or different than the thickness of any layer. Forexample, the depth D of the laser-etching can be the same as thepre-etching thickness T1 of the outer layer 40 or can be greater than orless than the pre-etching thickness the outer layer 40 and/or any otherlayer (e.g. pre-etching thickness T3 of inner layer 44 or T2 ofintermediate layer 42). The depth D of the etching may be less than thepre-etching thickness T1 of the outer layer 40 if it is desired that theouter layer 40 form the outer surface 33 of the perform 10.Alternatively, the depth D of the etching may be greater than thepre-etching thickness T1 of the outer layer 40 if it is desired for oneor more layers other than the outer layer 40 to form a portion of theouter surface 33 of the perform 10. Different depths D of etching canprovide different aesthetic, functional, and/or textural features on theresulting blow molded article as can different sizes and shapes of thelaser beam 50.

Typically, the depth of the etching is between about 0.001 mm to about 2mm, but any suitable depth of etching can be used. For example, anyetching or portion thereof can be up to about 90% of the thickness ofthe preform wall 30. In addition to the depth of the etch, the kerf (theslit or notch made by etching), can take any desired shape. For example,the shape of the kerf may follow a gaussian curve, where the kerf iswider at the top and narrower at the bottom. A kerf can also be in theshape of a non-tapered slit with generally vertical walls. Stillfurther, the shape of a kerf can follow other geometries like a reversetaper or barrel shaped taper. The depth of the etch can vary throughoutthe kerf and/or can be different in different portions of the texture orpredetermined pattern 54.

Laser:

As stated above, one method to create predetermined pattern 54 on theperform 10 is laser-etching. Any suitable laser can be used to etch thesurface of the perform 10. One example of a laser 52 useful foretching/ablating a perform 10 in accordance with the present inventionis a sealed carbon dioxide type laser, having power in the range of 40 Wto 2.5 kW, and a laser wavelength of 9 microns to 11 microns, or from9.4 microns to 10.6 microns. Such lasers are available from varioussuppliers, including an LPM1000 module, available in 30 LASERSHARPsystems from LasX Industries, Inc. of White Bear Lake, Minn., UnitedStates. Other makes and types of lasers are also possible and differentpower ranges and settings may be used. The laser 52 can include opticsthat can be used to change the energy density and/or spot size of thelaser beam, as desired.

Article:

Blow molded articles in accordance with the present invention may beprovided with unique and beneficial characteristics. The characteristicsare the result of unique features relating to the structure of thearticle itself, characteristics of the perform 10, and the method ofmaking the perform and/or blow molded article. FIGS. 4-6 show examplesof blow molded articles 100 in accordance with the present invention. Asnoted above, the present invention can provide aesthetic, functional,and textural features to blow molded articles 100 that were heretoforenot attainable and/or not attainable with currently available massproduction equipment and technology. For example, as shown in FIG. 4,blow molded articles 100 of the present invention may include one ormore article walls 150 surrounding an interior space 107 (shown in FIG.4A), a neck 103 with an opening 104 in fluid communication with theinterior space 107, a base 106, an article inner surface 132, and anarticle outer surface 133. The article 100 may include a texture 110 onthe article inner surface 132 or article outer surface 133 of the blowmolded article 100.

As shown in FIGS. 5 and 6, blow molded articles 100 in accordance withthe present invention may include one or more predetermined features105, such as aesthetic features 112. Examples of aesthetic featuresinclude, but are not limited to patterns, indicia, one or more colors,shading, gradation, appearance of depth, as well as other aestheticfeatures and combinations thereof. Generally, the aesthetic feature(s)112 of the article 100 are visible by users under ordinary useconditions. However, embodiments are contemplated wherein the aestheticfeature(s) 112 or portions of the aesthetic feature(s) 112 are visibleonly under certain circumstances, such as when the article 100 is filledwith a product or material, partially filled or when the article 100 isempty or partially empty. Functional features include, but are notlimited to, features such as increase or decrease of strength, increaseor decrease of flexibility, increase or decrease of coefficient offriction, structure that creates ribs, ramps, protuberances, valleys, orother structures that provide some function to the article 100. The blowmolded articles 100 of the present invention may be single or multilayerarticles 100. In multilayer articles 100, there may be two or morelayers. For example, as shown in FIGS. 4A and 4B, article 100 may have afirst layer 140 forming the article outside surface 133 of the article100, a third layer 144 forming an inside surface 132 of the article 100,and a second layer 142 sandwiched between the first layer 140 and thethird layer 144, wherein the layers together make up the entire wall 150of the article 100 in that region. Generally, the multilayer region(i.e. the region comprising more than one layer) makes up a majorportion or the entirety of the article 100 wall 150 surface, butembodiments are contemplated wherein at least a portion of the article100 includes fewer than all of the layers disposed in at least anotherregion of the article 100. For example, one or more of the layers maynot extend the entire distance from the neck 103 to the base 106 of thearticle 100.

The walls 150 of the article 100 can be any suitable thickness. Forexample, the wall thickness TW (shown in FIG. 4A) may range from about0.1 mm to about 3.0 mm, although other thicknesses are possibledepending on the particular process used and the desired end result.Also, the relative thickness of the layers, if any, can be differentfrom each other and can vary throughout the particular layer. That iseach of the layers may have a thickness that is different from the otherlayers or some or all may have thicknesses that are approximately thesame. Generally, each layer is somewhere between 5% and 100%, 5% and75%, 5% and 50%, or 5% and 40% of the total thickness of the articlewall. And, as noted above, different portions of the walls 150 and/orlayers may have different thicknesses, as desired.

One or more of the layers or portions of any layer in the blow moldedarticle 100 may be transparent, translucent or opaque. Likewise, one ormore of the layers or portions thereof may include one or more pigmentsor other color-producing material. In such instances, one or more of thelayers may be visible through one or more of the other layers. Thepresence of a smooth transparent outside layer can help allow forpigments in other layers to be visible from outside of the article 100and can at the same time provide the article 100 with gloss. Withoutbeing bound by theory, it is believed that the presence of a glossysurface at a distance from a translucent or opaque layer that includespigments can create an effect of “depth” which can contribute to apremium appearance of the article itself. It can also give theappearance that the article 100 is made from glass or a material otherthan a thermoplastic material.

One especially advantageous and unique aspect of the present inventionis that it allows for blow molded articles 100 to be formed with avisual impression of texture on the article outer surface 133 of thearticle 100, even where the article outer surface 133 or portionsthereof are smooth relative to the texture or visual impression oftexture. As shown in FIG. 4, a relatively smooth article outer surface133 with visually-apparent texture may be, for example, achieved whenthe texture 110 is formed on the inner surface 132 of the article 100,and at least a portion of the one or more layers of the wall 150 of thearticle 100 is/are transparent or translucent. A smooth article outersurface 133 can be advantageous, for example, when applying a label 115to a portion of the article outer surface 133 of the article 100,especially when the label 115 is intended to adhere to the article outersurface 133, such as, for example, pressure sensitive labels, shrinklabels, direct object printing, wrap around labels, screen printing,in-mold labels, transfer labels, pad printing and any other labels,printing or materials placed on or adjacent the outer surface 133. Asmooth article outer surface 133 can also be desirable when the articleouter surface 133 is to be printed, when a shrink label is used, and/orfor other reasons, including “feel”, processing, look, etc.

As shown in FIGS. 4A and 4B, the article 100 may have a predeterminedfeature 105, such as texture 110 disposed on a portion 120 of thearticle 100. The texture 110 may create all or a portion of an aestheticfeature 112, as set forth herein. In the example shown, the texture 110is disposed on the inner surface 132 of the article, but embodiments arecontemplated wherein the texture 110 is disposed on the article outersurface 133 and or both the article inner surface 132 and the articleouter surface 133. The texture 110 is shown as being created byvariations in the thickness T6 of the inner layer 144 of the article.The predetermined feature 105 can also provide a functional feature suchas a rib, rifling or other structure. The texture 110 is the result ofthe etching done to the perform 10 that was used to form the article 100and the blow molding process itself.

The predetermined feature 105 results from the perform 10 from which thearticle 100 is made being manipulated prior to expanding the article 100to its final shape. The predetermined feature 105 may include etchedregions 111 and non-etched regions 113. The etched regions 111correspond to the areas of the article 100 that were etched when thearticle was a perform 10 and not yet expanded to its final shape. Thenon-etched regions 113 are regions or the article 100 that correspond toregions of the perform 10 that were not etched prior to being expandedinto the final article 100. The etched regions 111 may be flush with orextend inwardly or outwardly from the non-etched regions 113 of theouter surface 133 of the article 133. It may be desirable that if theetched regions 111 extend inwardly or outwardly from the non-etchedregions 113, they do so no more than a pre-determined amount to providethe outer surface 133 with a particular topography. For example,limiting the inward or outward extension of the etched regions 111 canhelp provide an outer surface 133 that is smooth to the touch and/or canreadily accept printing and/or a label, or other form of decoration.

As shown in FIG. 4B, the article 100 may have a first layer 140 having afirst thickness T4, a second layer 142 having a second thickness T5, anda third layer 144 having a third thickness T6. The first layer 140 isdisposed outwardly of the third layer 144. The first layer 140 includesthinned regions 152 that are thinner than the thickness T4 of the firstlayer 140 outside of the thinned regions 152. The thinned region 152 ofthe first thickness T4 may be less thick than at least a portion of thesecond thickness T5 and/or third thickness T6 overlying the thinnedregions T4. Thus, the predetermined feature 105 may be created byvariations in the thickness of one or more of the layers of the article100 in a predetermined pattern 54. As shown in FIGS. 4A and 4B, thefirst thickness T4 of the article 100 may vary more than the secondthickness T5 of the second layer 142 and/or the third thickness T6 ofthe third layer 144 through at least a portion of the predeterminedfeature 105.

FIGS. 4C-H show different examples of how the wall 150 of an article 100may look due to different etching depths made to the perform 10. FIG. 4Cshows the wall 30 of a perform 10 wherein the depth D of the etching isless than the thickness T1 of the outer layer 40. FIG. 4D shows how thewall 150 of an article formed from the perform 10 of FIG. 4C might lookafter the article 100 is formed. As shown, the portion of the wall 150shown includes three layers, a first layer 140, a second layer 142disposed inwardly of the first layer 140 and a third layer 144 that isdisposed inwardly of the second layer 142. The first layer 140 has aportion corresponding to the etching of the perform 10 that is thinnerthan the non-etched portion of the wall 150. FIG. 4E shows the wall 30of a perform 10 wherein the depth D of the etching is equal to thethickness T1 of the outer layer 40. FIG. 4F shows how the wall 150 of anarticle formed from the perform 10 of FIG. 4E might look after thearticle 100 is formed. As shown, the wall 150 shown includes threelayers, but the first layer 140 has a portion missing corresponding tothe etching of the perform 10. Thus, at least a portion of the outersurface 133 of the article 100 is formed by the second layer 142. FIG.4G shows the wall 30 of a perform 10 wherein the depth D of the etchingis greater than the thickness T1 of the outer layer 40. FIG. 4H showshow the wall 150 of an article formed from the perform 10 of FIG. 4Cmight look after the article 100 is formed. As shown, the wall 150includes three layers, but the article outer surface 133 has a portioncorresponding to the etching of the perform 10 that is made up of thethird layer 144. An article 100 can be formed from any number of layersand can include any number of textural, functional and/or aestheticfeatures 112 that have characteristics, e.g. different layers visibleand/or forming the outer surface 133 of the article 100.

FIGS. 5 and 6 are examples of bottles in accordance with the presentinvention. FIG. 5 shows an article 100, a bottle, with an aestheticfeature 112 visible on the article outer surface 133. The article hasthree layers of material forming the wall 150 of the article 100. Theouter layer of the article 100 is a different color than the middlelayer. The unique aesthetic feature 112 can be attributed to the factthat a portion of an inner layer of the article 100 is visible throughthe outer layer. The aesthetic pattern 112 is formed by laser-etchingthe perform used to make the article 100. Specifically, the outer layerof the perform is laser-etched in a predetermined pattern 54 and at apredetermined depth to allow the color of the middle layer of thearticle 100 to be visible through the outer layer. In the embodimentshown, the first layer 140 includes a material that provides a glosssurface. The article outer surface 133 is generally smooth despite thevisual impression of texture provided by the aesthetic feature 112.

The extent to which a particular surface is smooth can be expressed interms of various different surface topography measurements. Twomeasurements that have been found to be particularly helpful incharacterizing the surface topography of performs and articles inaccordance with the present invention are Maximum Peak/Pit Height (Sz)and Root Mean Square Roughness (Sq) as described below in theMeasurement Methods section of this specification. For example, it maybe desirable to limit the Maximum Peak/Pit Height across some or all ofthe article outer surface 133 and/or the Root Mean Surface Roughness theto provide a surface that is desirable for printing, and/or labeling, orfor other tactile, aesthetic or functional reasons. For example, it maybe desirable for the Sz of some or all of the article outer surface 133to be less than or equal to 750 microns, 500 microns, 250 microns, 200microns, 150 microns, 100 microns, or 50 microns. Additionally, oralternatively, it may be desirable for some or all of the etched regions111 to have an Sq of a certain value or below. For example, it may bedesirable for some or all of the etched regions 111 to have an Sq ofless than or equal to 10 microns, 8 microns, 5 microns, or 2 microns. Asa result of the process used to form the predetermined feature 105, suchas predetermined pattern 54, the inner surface 132 may have certaintopological characteristics as well. For example, some or all of theetched regions 111 of the inner surface 132 may have an Sq of greaterthan or equal to about 2 microns, 5 microns, 8 microns, or 10 micronsand the Sz of some or all of the article inner surface 132 may begreater than or equal to 50 microns, 100 microns, 150 microns, 200microns, 250 microns, 500 microns, or 750 microns.

FIG. 6 shows an article 100, a bottle, with an aesthetic feature 112visible on the article outer surface 133. The article has three layersof material forming the wall 150 of the article 100. The outer layer ofthe article 100 is a different color than the middle layer. The uniqueaesthetic feature 112 can be attributed to the fact that a portion of aninner layer of the article 100 is visible through the outer layer. Theaesthetic pattern 112 is formed by laser-etching the perform used tomake the article 100. Specifically, the outer layer of the perform islaser-etched in a predetermined pattern 54 and at a predetermined depthto allow the color of the middle layer of the article 100 to be visiblethrough the outer layer. In the embodiment shown, the first layer 140includes a material that provides a gloss surface. The article outersurface 133 is smooth relative to the visual impression of textureprovided by the aesthetic feature 112. Specifically, the article outersurface 133 or portion thereof that is smooth, for example, may have anSq of less than or equal to about 10 microns, 8 microns, 5 microns, or 2microns. Additionally, or alternatively, the article outer surface 133may have a topography created by the predetermined feature 105 having anSz that is less than or equal to 750 microns, 500 microns, 250 microns,200 microns, 150 microns, 100 microns, or 50 microns. As a result of theprocess used to form the predetermined feature 105, such aspredetermined pattern 54, the inner surface 132 may have certaintopological characteristics as well. For example, some or all of theetched regions 111 of the inner surface 132 may have an Sq of greaterthan or equal to about 2 microns, 5 microns, 8 microns, or 10 micronsand the Sz of some or all of the article inner surface 132 may begreater than or equal to 50 microns, 100 microns, 150 microns, 200microns, 250 microns, 500 microns, or 750 microns.

For any multi-layer article 100, the article outer surface 133 may beformed solely by the third layer 144 or may be formed partially by thethird layer 144 and at least partially by any other layer. For example,the article 100 may have a wall 150 that has an article outer surface133 formed mostly by the third layer 144 and partially by another layer.This can be the case when the outer layer 40 of the perform is etched toa depth that an underlying layer is exposed in the final article 100.This can provide the article 100 with unique visual and tactile featuresas the layers may have different characteristics, such as gloss,translucency, color, feel, etc.

Although the above examples are of a multi-layer article, mono-layerblow molded articles are also contemplated. For example, as shown inFIG. 6A, a mono-layered article 100 may be formed from a perform havinga thermally-etched predetermined pattern 54. An aesthetic, functional,and/or texture feature may be incorporated into the wall 150 of thearticle 100 such that it is visible from the exterior of the article100. The predetermined feature 105 may be formed from variations in thethickness of the wall 150 corresponding to the predetermined pattern 54.The predetermined pattern 54 may include regions or patterns that wereablated from the outer surface 33 or inner surface 32 of the perform 10(an example of which is shown in FIG. 6B) used to create the article100, such as, for example, by laser-etching. The mono-layer,laser-etched, blow molded article 100 may have an article outer surface133 or portion thereof that is smooth, for example, having an Sq of lessthan or equal to about 10 microns, 8 microns, 5 microns, or 2 microns.Additionally, or alternatively, the article outer surface 133 may have atopography created by the predetermined feature 105 having an Sz that isless than or equal to 750 microns, 500 microns, 250 microns, 200microns, 150 microns, 100 microns, or 50 microns. As a result of theprocess used to form the predetermined feature 105, such aspredetermined pattern 54, the inner surface 132 may have certaintopological characteristics as well. For example, some or all of theetched regions 111 of the inner surface 132 may have an Sq of greaterthan or equal to about 2 microns, 5 microns, 8 microns, or 10 micronsand the Sz of some or all of the article inner surface 132 may begreater than or equal to 50 microns, 100 microns, 150 microns, 200microns, 250 microns, 500 microns, or 750 microns.

The article 100 may be a container such as bottle 180 shown in FIGS. 7Aand 7B. The bottle 180 may be filled with a composition 182 such as apersonal care or home care composition. The bottle 180 may includeaesthetic features 112 that are enhanced or mitigated by the presence ofthe composition 182 in the bottle 180. For example, a composition 182 ina clear bottle 180 with a texture 110 on the article inner surface 132may result in the texture 110 being more, less or even non-apparentwhere the composition 182 is disposed adjacent the texture 110 thanwhere it is not. In one example, a white composition 182 in a clearbottle 180 with texture 110 on the inner surface may obscure the patternof the texture 110 where the composition 82 is disposed adjacent thetexture 110. However, the texture 110 may be clearly visible in regionswhere the composition 182 is not present, for example, the top portionof the bottle 180 when the bottle 180 is less than half-full of thecomposition 182. Similarly, other forms of color-matching between thebottle-color and the composition-color (e.g. a blue composition in ablue bottle) may result in the aesthetic feature 112 being more orless-apparent during the time the product is sold or used. Alternately,the aesthetic features 112 of the bottle 180 may be enhanced by thecomposition 182 therein. For example, choosing different colors for thecomposition 182 and the bottle 180 may result in the texture oraesthetic features 112 being visually enhanced when the composition 182is in the bottle 180. Often, colors are described in terms ofcolor-saturation (e.g. L in the L, a, b-scale) and hue, but other colorcharacteristics may also affect the aesthetics of the bottle-compositioncombination.

Another advantage of the present invention is that it can provide forpredetermined features 105 to be disposed on the inner surface 132 ofthe article 100 without the need to alter the inner surface 32 of theperform 10. Such predetermined features 105 may be simple in nature(e.g. straight, parallel lines) or complex (e.g. curved lines,non-parallel lines, dots, shapes, letters, indicia, and combinationsthereof). As noted above, by texturing the inner surface 132 of thearticle 100 as opposed to the article outer surface 133, the articleouter surface 133 can present a smooth surface that may be desired forits “feel” or to allow for more efficient and/or effective printing orlabeling of the surface. Further, however, the predetermined feature 105can still provide the article 100 with unique visual, tactile orfunctional characteristics. For example, if at least a portion of thewall 150 of the article 100 is transparent or translucent, a texture 110or aesthetic feature 112 can be provided on the inner surface 132 of thearticle 100 and is visible through the wall 150 of the article. If acolored or opaque composition 182 is included in the article 100, it ispossible to have the texture 110 or aesthetic feature 112 appearvisually to the user only after some of the composition 182 has beendispensed from the article 100. Also, providing a texture 110 on theinner surface 132 of an article 100 can be used to enhance or otherwisemodify a texture 110 or other aesthetic feature 112 that is disposed onthe article outer surface of the article or vice-versa.

Beyond purely aesthetic benefits, the predetermined feature 105 mayprovide the article 100 with one or more functional aspects alone or inaddition to any aesthetic or textural feature or benefit. For example,the bottle 180 with a certain aesthetic feature 112 or texture 110 canbe paired with a composition 182 such that the aesthetic feature 112 ortexture 110 is more of less visible after a certain amount of thecomposition 182 has been dispensed from the bottle 180. Thus, themanufacturer can incorporate a repurchase reminder or other informationinto the bottle 180 in ways that were heretofore not available. As such,consumers may find the product to be interesting and/or sophisticatedwhich may drive purchase intent and increase sales. Further, thepredetermined feature 105 may, for example, provide ribs or otherstructural features on the article inner surface 132 or article outersurface 133 to provide for improved strength and/or flexibility to allor parts of the article 100.

The predetermined feature 105 can be registered with any label 115,pigment, texture, graphic, or any other textural or aesthetic feature ofthe article 100. For example, it may be desirable to provide the article100 with a region of visual depth, or a texture 110 in a particularlocation to help enhance another feature of the article 100. To do so,the texture 110 and/or other aesthetic feature 112 can be registered orprovided in a pre-determined location such that the texture 110 and/oraesthetic feature 112 is located in the desired location on the finalarticle 100. Additionally, the present invention can provide theadditional benefit of not having to register labels and/or printing withcertain areas on the article 100 because the predetermined feature 105can be provided while still allowing for a generally smooth outersurface 133. Thus, it may provide a more cost efficient and effective topresent articles 100 for labeling or further decoration, etc. thansimilar articles with rough or uneven outer surfaces.

The pattern 54 etched onto the perform 10 can be designed so as toprovide the predetermined feature 105 on the article 100 after anydistortion that may result from the blowing of the perform 10 into thefinished article 100. For example, some or all of the features,patterns, indicia and the like comprising a predetermined pattern 54 onthe article 100 may be etched on the perform 10 in a pattern that isdistorted relative to its desired finished appearance, so that thefeatures, patterns, indicia and the like acquire their desired finishedappearance upon being formed into the three-dimensional article 100.Such pre-distortion printing may be useful for indicia such as logos,diagrams, bar-codes, and other images that require precision in order toperform their intended function.

Performs 10 and articles 100 according to the invention can compriselayers and/or materials in layers with various functionalities. Forexample, an article 100 may have a barrier material layer or a recycledmaterial layer between an outer thermoplastic layer and an innerthermoplastic layer. The article 100 may comprise, for example,additives typically in an amount of from 0.0001%, 0.001% or 0.01% toabout 1%, 5% or 9%, by weight of the article. Non-limiting examples offunctional materials include, but are not limited, to titanium dioxide,filler, cure agent, anti-statics, lubricant, UV stabilizer,anti-oxidant, anti-block agent, catalyst stabilizer, colorants,pigments, nucleating agent, and a combination thereof.

Method of Making Blow Molded Article:

As noted above, the article 100 of the present invention can be made byany known blow molding method, including IBM and ISBM. In such methods,the article 100 is formed from a perform 10, such as the one shown inFIG. 1. The perform 10 can be made by any known method, includinginjection, 3D printing or any other suitable method. FIG. 8 shows anexample of a perform 10 in an injection perform mold 200 after thematerial making up the perform 10 has been injected into the performmold cavity 215 of the perform mold 200 and the perform 10 has beenformed into the desired shape. The material making up the perform 10 isinjected into the mold through orifice 210. After the material is cooledor otherwise modified such that the perform 10 can maintain its shape,the perform 10 is removed from the mold 200. The perform 10 may besubjected to any number of post-molding techniques, including, but notlimited to chemical treatments, heating, cooling, light, mechanicalmanipulation, such as, for example, cutting, etching, scraping, bending,coating, etc. These techniques can help provide the perform 10 and/orfinal article 100 formed from the perform 10 desired properties.

In accordance with the present invention, the outer surface 33 of theperform 10 may be provided with a perform texture, such as, for example,in a pattern such as predetermined pattern 54. Although the performtexture could be provided by the perform mold 200, as noted above, suchprocesses are very limited in the perform textures that they can createdue to the requirement that the perform 10 be removed from the mold 200.As such, it is preferred that the perform 10 be provided with theperform texture after it is removed from the mold 200. As shown in FIG.9, the perform 10 may be laser-etched by one or more lasers 52. Thelaser(s) 52 can direct one or more laser beams 50 to modify or remove aportion of the outer surface 33 of the perform 10. The material ablatedor removed can create a pattern and/or a perform texture on the outersurface 33 of the perform 10. The predetermined pattern 54 or performtexture can include any number of lines, shapes, dots, curves, indicia,letters or combinations thereof. Any portion of the outer surface 33 ofthe perform may be laser-etched or otherwise modified and themodification process can take place at one time or in multiple differentsteps. The perform 10 may be rotated about its longitudinal axis Lduring etching to allow the etching device to etch the outer surface 33about the circumference of the perform 10 or the etching device may berotated about the perform 10, or both can be rotated.

Once the desired perform texture or pattern is applied to the perform10, the perform may be moved to a blow molding step to form the finalarticle 100 or may be stored or otherwise treated for differentproperties. Generally, just prior to the blow molding step, the perform10 is heated or otherwise treated to soften it from a hardened state.This allows the perform 10 to be more easily blown into the shape of thefinal article 100. Often, the perform is heated by lamps, hot air,radiation or convection, but other methods of heating the perform 10 canbe used. When the perform 10 is ready to be “blown” or expanded into theshape of the final article 100, it is placed into a blow mold, such asfor example, the one shown in FIG. 10. The blow mold 250 has a cavity260 formed by walls 270. The cavity 260 is the shape of the finalarticle 100. The walls 270 may be smooth or may have some texture. Theperform 10 in the mold 250 is expanded such that the walls 30 of theperform 10 contact the walls 270 of the blow mold 250 and take the shapeof the cavity 260. Generally, the perform 10 is expanded by forcing airor another fluid into the opening 34 of the perform through the open end16 of the perform. If desired, a vacuum created in the cavity 260 canassist the expansion of the perform 10. Once the perform 10 is expandedinto the shape of the mold 250 and thus, the final article 100, thearticle 100 can be cooled and the blow mold 250 can be removed. Thearticle 100 can be subjected to additional processing steps, includingbut not limited to inspection, removal of imperfections, cleaning,filling, labeling, printing, and sealing.

It is possible to configure the blowing process such that some or all ofthe perform texture creates a texture 110 of the article 100.Surprisingly, the blow molding process can be configured to create thetexture 110 on the inner surface 132 of the article 100, the oppositesurface of the wall 150 where it was originally etched or otherwisecreated. This is especially surprising for thermal etching on theexternal surface of the perform 10. In order to reach temperaturessufficient for thermal ablation and material vaporization, typically azone of melted or heat affected material is generated. This melted orheat affected zone can create thermally induced crystallization on theexternal surface. Crystallized material resists stretching and reformingto the surface of the blow cavity and tends to rebound from the surfaceof the blow mold. In order to create a smooth outer surface 133, theamount of thermal crystallization on the external surface should becontrolled (via efficient ablation on the external surface), the blowingparameters need to be optimized to 1) minimize additional thermal andstrain induced crystallization on the external surface and 2) Set thematerial in the mold to avoid concave or convex surfaces in thetransition from thick to thin surfaces (see chart that describes blowmolding parameters that enable this).

For example, if the perform 10 was laser-etched on the outer surface 33,the final blow molded article 100 can have a texture 110 correspondingto the laser-etching pattern on its inner surface 132. This transfer ofthe perform texture to the inner surface 132 of the article 100 canallow the article 100 to have unique and aesthetically pleasing featurescompared to previously known blow molded articles 100. One example, asdescribed in more detail above, is a bottle having a smooth articleouter surface and an aesthetic feature 112 that gives the appearance ofthickness, depth and/or texture to the bottle. Such aesthetic featurescan make the bottle more attractive and more consumer preferred.Additionally, because the article 100 can be provided with a smootharticle outer surface 133, it can be more easily labeled and/or haveprinting applied thereto. Further still, because the method provides away to add a texture, pattern or functional feature to the perform 10after it is out of the perform mold 200, it can significantly simplifythe process for making complex features on the end article 100. Thisalso allows for the functional, textural and/or aesthetic features ofthe end article 100 to be changed despite the perform 10 being from thesame perform mold 200 and allows for much quicker and more efficientchanges to the overall aesthetics, texture or functional features of thearticle 100 because new perform molds 200 are not needed if it isdesired to change the resulting article 100. Thus, small productionsbatches and even customized articles become economically feasible.

Measurement Methods:

Wall thickness, layer thickness, maximum peak/pit height (Sz), and rootmean square roughness (Sq), as used herein, are measured as set forthbelow.

Wall Thickness

Wall Thickness is measured with a digital micrometer, such as a Shinwa79523 Digital Micrometer having an accuracy of +/−0.003 mm, at two ormore locations in the region of the article where the wall thickness isto be measured.

Layer Thickness

Layer thickness is measured with an industrial microscope, such asOlympus BX Series Optical Microscope having an accuracy of 0.003 mm, attwo or more locations in the region of the article where the layerthickness is measured.

Sz—Maximum Peak/Pit Height:

Sz, the Maximum Peak/Pit Height, is measured using a 3D Laser ScanningConfocal Microscope such as a Keyence VK-X200 series microscopeavailable from KEYENCE CORPORATION OF AMERICA) which includes a VK-X200Kcontroller and a VK-X210 Measuring Unit. The instrument manufacturer'ssoftware, VK Viewer version 2.4.1.0, is used for data collection and themanufacturer's software, Multifile Analyzer version 1.1.14.62 and VKAnalyzer version 3.4.0.1, are used for data analysis. If needed, themanufacturer's image stitching software, VK Image Stitching version2.1.0.0, can be used. The manufacturer's analysis software is compliantwith ISO 25178. The light source used is a semiconductor laser with awavelength of 408 nm and having a power of about 0.95 mW.

The sample to be analyzed is obtained by cutting a piece of the articleout of the article that includes the region to be analyzed in a sizethat can fit the microscope for proper analysis. To measure Sz of anarticle with etched and non-etched regions 113, a sample should beobtained that includes both the etched and non-etched regions 113. Theanalysis should take place over both the etched and non-etched regions113. If the etched region has one axis that is longer than another, thelong axis of the etched region to be measured should be orientedapproximately perpendicular to the long axis of the image region. If thesample is not flat, but flexible, the sample may be flattened and helddown on the microscope stage with tape or other means. If, due to theshape, flexibility or other characteristic of the sample, measurementswill be more accurate when the sample is not flattened, corrections maybe used, as explained hereinbelow.

Sz is obtained by acquiring and stitching together several contiguousimages of the sample in the region of interest (e.g. a region includingboth etched and non-etched areas). The images are collected using 10×objective lens suitable for non-contact profilometry such as a 10× NikonCF IC Epi Plan DI Interferometry Objective with a numerical aperture of0.30, giving an image area of approximately 1430×1075 micrometers perimage. The images are automatically stitched using the manufacturer's“VK Image Stitching” software. Data is acquired from the images usingthe acquisition software's “Expert Mode” wherein the followingparameters are set as described herein: 1) Height Scan Range is set toencompass the height range of the sample (this can vary from sample tosample depending on the surface topography of each); 2) Z-direction stepsize is set to 2.0 micrometers; 3) Real Peak Detection mode is set to“On”; and 4) Laser Intensity and Detector Gain are optimized for eachsample using the autogain feature of the instrument control software.

Prior to analysis, the data is subjected to the following correctionsusing the manufacturer's Multifile Analyzer software: 1) 3×3 mediansmoothing in which the center pixel of a 3×3 pixel array is replaced bythe median value of that array; 2) noise removal using strong height cut(following built in algorithm in the analysis software), and 3) shapecorrection using the simplest method (plane, second order curve orwaveform removal) sufficient to remove the shape of the surface. Regionsincluding foreign materials, artifacts of the sample harvesting processor any other obvious abnormalities should be excluded from analysis andalternative samples should be used any sample can't be accuratelymeasured. The shape of the surface is removed using the Waveform Removalmethod of the Surface Shape Correction tool. The cutoff wavelength isspecified to be approximately five times the size of the largeststructure to be preserved. The Reference Plane is specified using theSet Area method and selecting the same area as is used for the shaperemoval. The resulting value is the Sz for the measured portion of thearticle.

Root Mean Square Roughness (Sq)

Root Mean Square Roughness, Sq, is measured using a 3D Laser ScanningConfocal Microscope such as a Keyence VK-X200 series microscopeavailable from KEYENCE CORPORATION OF AMERICA) which includes a VK-X200Kcontroller and a VK-X210 Measuring Unit. The instrument manufacturer'ssoftware, VK Viewer version 2.4.1.0, is used for data collection and themanufacturer's software, Multifile Analyzer version 1.1.14.62 and VKAnalyzer version 3.4.0.1, are used for data analysis. If needed, themanufacturer's image stitching software, VK Image Stitching version2.1.0.0, can be used. The manufacturer's analysis software is compliantwith ISO 25178. The light source used is a semiconductor laser with awavelength of 408 nm and having a power of about 0.95 mW.

The sample to be analyzed is obtained by cutting a piece of the articleout of the article that includes the region to be analyzed in a sizethat can fit the microscope for proper analysis. To measure Sq of anetched portion of an article, a sample should be obtained that includesan etched region and the analysis should take place only over theportion of the sample that is etched. If the sample is not flat, but isflexible, the sample may be held down on the microscope stage with tapeor other means. If, due to the shape, flexibility or othercharacteristic of the sample, measurements will be more accurate whenthe sample is not flattened, corrections may be sued, as explainedhereinbelow.

The measurement data from the sample is obtained using a 20X objectivelens suitable for non-contact profilometry, such as a 20× Nikon CF ICEpi Plan DI Interferometry Objective with a numerical aperture of 0.40.The data is acquired using the acquisition software's “Expert Mode”,with the following parameters set as described he: 1) Height Scan Rangeis set to encompass the height range of the sample (this can vary fromsample to sample depending on the surface topography of each); 2)Z-direction Step Size is set to 0.50 micrometers; 3) Real Peak Detectionmode is set to “On”; and 4) Laser Intensity and Detector Gain areoptimized for each sample using the autogain feature of the instrumentcontrol software.

Prior to analysis, the data is subjected to the following correctionsusing the manufacturer's Multifile Analyzer software: 1) 3×3 mediansmoothing in which the center pixel of a 3×3 pixel array is replaced bythe median value of that array; 2) noise removal using weak height cut(following built in algorithm in the analysis software), and 3) shapecorrection using waveform removal (0.5 mm cutoff). The Reference Planeis specified using the Set Area method and selecting the same area as isused for the shape removal. Regions including foreign materials,artifacts of the sample harvesting process or any other obviousabnormalities should be excluded from analysis and alternative samplesshould be used any sample can't be accurately measured. The resultingvalue is the Root Mean Square Roughness, Sq, for the measured portion ofthe sample.

All percentages are weight percentages based on the weight of thecomposition, unless otherwise specified. All ratios are weight ratios,unless specifically stated otherwise. All numeric ranges are inclusiveof narrower ranges; delineated upper and lower range limits areinterchangeable to create further ranges not explicitly delineated. Thenumber of significant digits conveys neither limitation on the indicatedamounts nor on the accuracy of the measurements. All measurements areunderstood to be made at about 25° C. and at ambient conditions, where“ambient conditions” means conditions under about one atmospherepressure and at about 50% relative humidity.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm ”

Every document cited herein, including any cross referenced or relatedpatent or application and any patent application or patent to which thisapplication claims priority or benefit thereof, is hereby incorporatedherein by reference in its entirety unless expressly excluded orotherwise limited. The citation of any document is not an admission thatit is prior art with respect to any invention disclosed or claimedherein or that it alone, or in any combination with any other referenceor references, teaches, suggests or discloses any such invention.Further, to the extent that any meaning or definition of a term in thisdocument conflicts with any meaning or definition of the same term in adocument incorporated by reference, the meaning or definition assignedto that term in this document shall govern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. A multi-layer blow molded article formed from aperform etched in a predetermined pattern, the article comprising: aneck forming an opening; a body portion extending from the neck to abase, the body portion including one or more walls surrounding aninterior space in fluid communication with the opening, the one or morewalls having an article inner surface, an article outer surface, and athickness; a predetermined feature incorporated into at least a portionof the one or more walls, wherein the predetermined feature is providedby variations in the thickness of the one or more walls corresponding tothe predetermined pattern.
 2. The multi-layer blow molded article ofclaim 1 wherein the one or more walls include a first layer having afirst thickness and a second layer having a second thickness, whereinthe first thickness changes throughout predetermined feature more thanthe second thickness in the same area.
 3. The multi-layer blow moldedarticle of claim 2 wherein the second layer is disposed inwardly of thefirst layer, and further comprising a third layer disposed inwardly ofthe second layer and forming an article inner surface.
 4. Themulti-layer blow molded article of claim 1 wherein the predeterminedfeature creates a topography on the outer surface, the topography havinga Maximum Peak/Pit Height, Sz, less than 750 microns.
 5. The multi-layerblow molded article of claim 1 wherein the article includes a labeldisposed at least partially over the portion of the article outersurface corresponding to the predetermined feature.
 6. The multi-layerblow molded article of claim 1 wherein the outer surface has at least aportion which corresponds to the predetermined feature, at least theportion of the predetermined feature includes one or more etchedregions, and wherein at least one of the etched regions has a Root MeanSquare Roughness of less than or equal to 10 microns.
 7. The multi-layerblow molded article of claim 1 wherein the one or more walls include afirst layer and a second layer, wherein the first layer is a differentfrom the second layer in at least one of the following characteristics:color, material, thickness, additive, pigment, opacity, gloss, opticalproperty, amount of recycled material, type of recycled material, orstrength.
 8. The multi-layer blow molded article of claim 1 wherein thearticle has at least one layer that does not extend from the neck to thebase.
 9. The multi-layer blow molded article of claim 1 wherein the wallhas a first layer and a second layer, wherein the first layer isdisposed outwardly of the second layer and includes a portion that istranslucent or transparent.
 10. The multi-layer blow molded article ofclaim 1 wherein the wall has a first layer and a second layer, thesecond layer disposed inwardly of the first layer, wherein the secondlayer forms at least a portion of the article outer surface of thearticle and forms at least a portion of the predetermined feature. 11.The multi-layer blow molded article of claim 1 wherein the article has afirst layer having a first thickness and a second layer having a secondthickness, the first layer being disposed outwardly of the second layer,and wherein the predetermined feature includes a thinned region of thefirst layer that is less thick than at least a portion of the firstlayer outside of the thinned region.
 12. The multi-layer blow moldedarticle of claim 1 wherein the article has a first layer has a firstthickness and a second layer has a second thickness, the first layerdisposed outwardly of the second layer, and wherein the aestheticfeature includes a thinned region of the first thickness that is lessthick than at least a portion of the second thickness underlying thethinned region of the first thickness.
 13. The multi-layer blow moldedblow molded article of claim 1 wherein the predetermined patternincludes ablated regions.
 14. A multi-layer perform for blow moldingformed from a thermoplastic material, the perform comprising: a bodyhaving one or more walls and an opening, wherein at least a portion ofthe body includes an etched portion having at least some of thethermoplastic material removed in a predetermined pattern.
 15. Theperform of claim 15 wherein the etching is thermal-etching.
 16. Theperform of claim 15 wherein the etching is performed by a laser.
 17. Theperform of claim 15 wherein the one or more walls of the perform have anouter layer and an inner layer, each having a thickness, and wherein theetching has a depth that is less than or equal to the thickness of theouter layer.
 18. The perform of claim 15 wherein the one or more wallsof the perform have an outer layer and an inner layer, and wherein theouter layer is translucent or transparent.
 19. The perform of claim 15wherein the one or more walls of the perform have an outer layer and aninner layer, each having a thickness, and wherein the etching has adepth that is greater than or equal to the thickness of the outer layer.20. The perform of claim 15 wherein the one or more walls of the performhave an outer layer and an inner layer, the inner layer being differentfrom the outer layer in at least one of the following: thickness,materials, colors, levels of translucency.